Garment including selectively located ventilation panels of three-dimensional mesh

ABSTRACT

A garment, including: a garment shell; and a ventilation region, wherein the ventilation region comprises a three-dimensional mesh member attached to the garment shell. Other features, and a method of manufacturing a garment, are also described.

TECHNICAL FIELD

This patent application relates generally to garments, such as jackets and pants, and more specifically, recreational clothing having panels of three-dimensional mesh for improved ventilation.

BACKGROUND

Clothing for people with an active lifestyle has existed for a number of years. For example, such clothing is typically used during recreational activities such as hiking, climbing, skiing, and other outdoor activities. Additionally, recreational clothing is often worn for everyday life activities. Examples of recreational clothing include at least, for example, jackets, shirts, pants, shorts, and other types of outerwear. Due to body heat that may be generated during recreational activities, there is often a need for recreational clothing to provide adequate ventilation. Additionally, in order to protect against inclement weather, there is often a need for the clothing to be waterproof while providing sufficient breathability and ventilation to the wearer.

SUMMARY

According to an embodiment, a garment is disclosed comprising: a garment shell; and a ventilation region, wherein the ventilation region comprises a three-dimensional mesh member attached to the garment shell.

According to another embodiment, a garment is disclosed comprising a three-dimensional mesh panel; and an outer layer; wherein the three-dimensional mesh panel comprises a face and an edge; wherein the outer layer overlays the three-dimensional mesh panel; wherein the three-dimensional mesh panel is connected to the outer layer at the edge of the three-dimensional mesh panel and the face of the three-dimensional mesh panel is at least partially disconnected from the outer layer.

According to another embodiment, a method for manufacturing a garment is disclosed comprising providing a plurality of outer garment layer panels; providing a three-dimensional mesh panel; attaching the three-dimensional mesh panel to at least one of the outer layer panels to form at least one ventilation garment panel; and attaching the plurality of outer garment layer panels to form the garment.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features and advantages will be apparent from the following, more particular, description of various exemplary embodiments, as illustrated in the accompanying drawings, wherein like reference numbers generally indicate identical, functionally similar, and/or structurally similar elements.

FIG. 1 is a front view of an embodiment of a jacket;

FIG. 2 is a front-right perspective view of the jacket of FIG. 1;

FIG. 3 is an enlarged view of an embodiment of a front fastener region of the jacket of FIG. 1;

FIG. 4 is a front-right perspective view of an interior of the jacket of FIG. 1;

FIG. 5 is a front view of the interior of the jacket of FIG. 1;

FIG. 6A is an enlarged front view of a portion of a yoke region of the jacket of FIG. 5;

FIG. 6B is an enlarged front view of a portion of a hood of the jacket of FIG. 5;

FIG. 7 is an enlarged cross-sectional view of a portion of a vent of FIG. 5; and

FIG. 8 is an enlarged, perspective, cross-sectional view of a portion of a vent of FIG. 5.

DETAILED DESCRIPTION

Various embodiments of the invention are discussed in detail below. While specific embodiments are discussed, it should be understood that this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components and configurations may be used without departing from the spirit and scope of the invention.

As used herein, terms such as “horizontal” and “x-y” when referring to, for example, a material, is used to describe the direction of the surface or face of the material, while terms such as “vertical” and “z-” are used to describe the direction perpendicular to the surface or face of the material and is also referred to as the “depth” or “thickness” of the material. Terms such as “horizontal,” “x-y,” “vertical,” “z-,” “first,” “second,” “inner,” “outer,” “front,” and “back” are used to describe positions relative to one another only and not to denote an absolute position. For example, a “vertical” or “z-” portion may become a “horizontal” or “x-y” portion by rotating the item, although it may still be referred to as a “vertical” portion of the item. In the same manner, a “first portion” may become a “second portion” by rotating the item.

Embodiments may provide garments that selectively combine waterproof materials and ventilation. For example, a jacket may include a shell of waterproof and breathable materials, as well as ventilation panels of mesh fabrics, for air flow and ventilation. Although the term “jacket” may be used to describe embodiments of the invention, a person skilled in the relevant art will recognize that other garments or clothing, such as shirts, vests, pants, and other garments may be used without departing from the spirit and scope of the injection.

A material is “two-dimensional” if the material is comprised of x-y (horizontal) components but does not have a significant z-(vertical) component. A two-dimensional material may include a single layer of material, such as a single knit or woven layer. A two-dimensional material may also include a thin, multi-layer laminate, such as a waterproof breathable laminated fabric such as, for example, GORE-TEX® made by W.L. Gore & Associates, Inc. of Newark, Del., or DVstorm made by eVent of Overland Park, Kans. A material that has a noticeable vertical component may be considered “three-dimensional.” A three-dimensional material may include multiple layers of material that are interconnected, such as a double knit material. In an embodiment, a three-dimensional fabric may include a first knit layer created by a stitch yarn and a second knit layer created by a stitch yarn, the first knit layer and second knit layer interconnected with a pile yarn. The interconnecting yarns may be spaced such that the three-dimensional fabric may provide for a “space” or “void” between the layers of material.

Embodiments may provide a shell of waterproof breathable material including panels of mesh that aid in ventilation. The mesh may comprise a two or three-dimensional knitted, woven, or non-woven material or combination thereof. In some embodiments, the mesh may be comprised of a continuously knitted or woven material with a significant z-direction component. According to an embodiment, the mesh is comprised of two knit or woven layers of x-y components, with z-oriented pile fibers or yarns interconnecting the two substantially two-dimensional layers. In the above described mesh, the two knit or woven layers contain pores, and the z- or vertically oriented fibers create an air space to distance the shell of the garment away from the skin or clothing of the wearer to provide a space for air flow. According to an embodiment, the mesh may comprise a 100% polyester, double knit, 2 mm mesh made by Burltex in Hong Kong, China; however, other materials are possible.

Embodiments may provide garments that selectively combine waterproof materials and ventilation. For example, a jacket may include a shell of waterproof and breathable material, as well as ventilation panels of mesh fabrics for air flow and ventilation. According to embodiments, the shell material may have an outer face fabric, a waterproof breathable membrane, and an inner liner laminated together. According to embodiments, the mesh fabric may be attached on the inside of the garment to the inner liner.

Referring to FIGS. 1-5, an embodiment of a jacket 10 is shown. The jacket 10 may generally include a plurality of panels 12, 14, 23, 24, 25, 26, 32, 34, 36, 40, and 44. For example, at least one of the plurality of panels may be a vent panel, such as front selective vent panel 16. For example, at least another one of the plurality of panels may be a ventilation panel 30, 42 (see FIG. 4). As described in more detail below, the jacket 10 may include a shell and a three-dimensional mesh. For example, the shell may be a waterproof-breathable material that is a substantially solid fabric. According to an embodiment, the three-dimensional mesh may extend over selective areas of the shell (e.g., on the interior) to selectively allow for direct air flow between the inside of the jacket and the outside of the jacket. For example, the jacket 10 may include a front selective vent panel 16 on the first front panel 12 that extends down the front of the wearer's torso. According to an embodiment, the front selective vent panel 16 is located on a first front panel 12 adjacent to first fastening member 18. According to embodiments, the fastening members 18, 22 may comprise a zip fastener, hook and loop, snap fastener, button, or other fastener known in the art, or a combination thereof.

Referring now to FIGS. 1-3, the jacket 10 may include a first front panel 12 having a close-side first fastening member 18 located adjacent to the front selective vent panel 16 closest to the second front panel 14, and a far-side first fastening member 20 located adjacent to the front selective panel 16 farthest from the second front panel 14. According to an embodiment, the jacket may also include a second fastening member 22 on the second front panel 14 that may be selectively fastened to either the close-side first fastening member 18 or the far-side first fastening member 20. The wearer may selectively connect the far-side first fastening member 20 to the second fastening member 22 so that the front vent panel 16 is connected inside the jacket 10 underneath the waterproof-breathable shell material. Alternatively, the wearer may selectively connect the close-side first fastening member 18 to the second fastening member 22 (as shown in FIG. 1), so that the front vent panel 16 spans between adjacent panels 12, 17 of waterproof-breathable shell material, thereby venting the wearer's body heat and cooling the wearer by evaporative cooling.

According to embodiments, the second fastening member 22 may comprise a zipper track, and the first fastening members 18, 20 may comprise complementary zipper tracks such that the second fastening member 22 may engage with either first fastening members 18, 20 with a zipper slide. According to embodiments, one or more zipper slides may reside on any of second fastening member 22, and first fastening members 18, 20. According to embodiments, multiple zipper tracks may reside on a fastening member to allow for selectively engaging the complementary zipper track.

As mentioned above, and as further shown in FIG. 3, the second fastening member 22 may be configured to engage with either the close-side first fastening member 18 or the far-side first fastening member 20. For example, as shown in FIGS. 1 and 2, when the second fastening member 22 is engaged with the close-side first fastening member 18, the front selective vent panel 16 is uncovered or unobstructed to allow for air movement between the inside of the jacket 10 and the outside of jacket 10. According to an embodiment, when the second fastening member 22 is engaged with the far-side first fastening member 20, the front selective vent panel 16 is substantially covered in order to, for example, protect the wearer and the inside of the jacket 10 from precipitation and the elements. The front selective vent panel 16 may be attached to the shell fabric of the first front panel 12 by, for example, stitching, bonding, laminating, ultrasonic welding, taping, or other technique known in the art, to form a seam on the inside face of the jacket 10.

In an embodiment, a ventilation panel may comprise a three-dimensional mesh located inside the jacket 10 such that the mesh face contacts either the wearer's skin or clothing. According to an embodiment, the three-dimensional mesh is substantially covered on the exterior face of the jacket 10 by a shell material that is substantially the same shape as the three-dimensional mesh. According to an embodiment, the three-dimensional mesh material may have a thickness or z-direction that is greater than the thickness of the shell material.

Due to the thickness of the three-dimensional mesh used in the ventilation panels, the mesh can lift the water-proof breathable shell material away from the wearer's body or mid/under layers. The mesh may define an open lattice through which air flow is possible, allowing body heat and air to flow freely through the mesh from the wearer to the shell material. By elevating the shell material away from the wearer's body via the mesh, a wearer's body may cool by evaporative cooling. Additionally, the likelihood of the shell material becoming saturated with perspiration is reduced, preserving the waterproof nature of the waterproof-breathable shell material.

Referring to FIGS. 4 and 5, embodiments of the plurality of ventilation panels are described in more detail. The jacket may include a yoke ventilation panel 30 comprising a three-dimensional mesh located inside the jacket 10 at a yoke region near a front shoulder and extending across the upper back of the wearer to the opposite front shoulder, such that the mesh face of the yoke ventilation panel 30 contacts either the wearer's skin or clothing. According to an embodiment, the yoke ventilation panel 30 is substantially covered on the exterior face of the jacket 10 by the yoke panel 32 comprised of shell material. For example, the three-dimensional mesh of the yoke ventilation panel 30, as shown in FIG. 6B, is substantially the same shape and size as the yoke panel 32, as shown in FIGS. 1 and 2; however, according to alternative embodiments, the yoke ventilation panel 30 and the yoke panel 32 can have different shapes and sizes from one another. As shown in FIGS. 5 and 6B, the edge of the three-dimensional mesh of the yoke ventilation panel may interface the shell material, and according to embodiments, the edges of the three dimensional mesh are connected to the shell material by stitching to form seam 30 a on the inside face of the jacket 10. As an alternative to sewing the mesh to the outer shell material, the mesh may be attached to the shell by seam sealing all or a portion of the mesh (e.g., the outer perimeter) to the outer shell material using seam sealing techniques known in the art.

According to an embodiment, the jacket 10 may include a hood 40 comprising a hood ventilation panel 42 located inside the hood 40. The hood ventilation panel 42 may be substantially covered on the external face of the hood by the exterior hood panel 44 comprising shell material. Thus, the exterior hood panel 44 may protect the head of a wearer from precipitation and the elements, while the hood ventilation panel 42 located within the interior of the exterior hood panel 44 allows air to flow freely through the mesh between the wearer and the shell material. For example, the three-dimensional mesh of the hood ventilation panel 42, as shown in FIGS. 4 and 5, may be substantially the same shape and size as the exterior hood panel 44, as shown in FIGS. 1 and 2; however, according to alternative embodiments, the hood ventilation panel 42 and the hood panel 44 may be different shapes and sizes from one another. According to embodiments, the edges of the three-dimensional mesh of the hood ventilation panel 42 are connected to the shell material of the exterior hood panel 44 by stitching to form seams on the inside face of the hood 40. As an alternative to sewing the mesh to the outer shell material, the mesh may be attached to the shell by seam sealing all or a portion of the mesh (e.g., the outer perimeter) to the outer shell material using seam sealing techniques known in the art.

In embodiments, a garment is constructed by piecing together a plurality of separate panels to form a garment of the desired shape. For example, a garment may be constructed by determining the shape of the desired finished garment; determining the shape and configuration of the plurality of panels; determining the placement of panels that will include a ventilation panel; providing the plurality of shell panels of a shell material; providing at least one or more of three-dimensional mesh panels corresponding to the shape of the determined at least one or more of the plurality of shell panels to be the ventilation panel; affixing the three-dimensional mesh panel to the shell panel to form the ventilation panel; and affixing the shell panels and the ventilation panels together to form the garment. In embodiments, any of the plurality of panels may be selected to be the ventilation panel based on, for example, the type of garment, desired ventilation in a particular body region of a wearer, and the activity the garment is intended for. In other embodiments, the mesh doesn't necessarily correspond to a shell panel and may be formed as an “island” on a larger shell panel, or the mesh may be placed over multiple panels of shell material that are joined together.

Referring again to FIGS. 1 and 2, embodiments of jacket 10 are constructed by piecing together and connecting separate panels by stitching or sealing to form a seam. For example, as shown in FIGS. 1 and 2, the yoke panel 32 may be joined to the first and second front panels 14 and 16 by stitching along the edges of the respective panels to form seams 32 a and 32 b across the front chest region. According to embodiments, the seam joining two panels may be extended continuously to join an adjacent panel. For example, as can be seen in FIGS. 1 and 2, seams 32 a and 32 b may be extended continuously to join the yoke panel 32 to the first and second side panels 34 and 36, respectively. However, other configuration of panels are possible.

Referring to FIGS. 7 and 8, the plurality of ventilation panels 30, 42 may include an inner layer of three-dimensional mesh 48 and an outer layer of shell material, outer shell 56, that overlays or covers the three-dimensional mesh 48. As shown in FIG. 7, the three-dimensional mesh 48 may comprise an inner mesh face 50 that contacts the wearer's skin or clothing, an outer mesh face 52 that contacts the inside surface of the outer shell 56, and mesh pile fibers 54 that interconnect the inner mesh face 50 and the outer mesh face 52. According to embodiments, the three-dimensional mesh 48 is connected along its periphery to an inner layer of shell material, inner shell 58. The inner shell 58 may then be connected to the outer shell 56 such that the outer mesh face 52 is adjacent to and at least partially disconnected from the inner face of the outer shell 56.

According to an embodiment, the three-dimensional mesh 48 may be connected to the inner shell 58 by stitching to form seams extending around all or a part of the mesh panel's perimeter. See, for example, seams 58 a and 58 b. As an alternative (or addition) to stitching, all or a portion of the mesh panel's perimeter may be seam sealed to the inner shell 58. According to an embodiment, the inner shell 58 may be connected to the outer shell 56 at seams 56 a and 56 b by stitching and/or seam sealing or taping. As is apparent from FIG. 8, outer mesh face 52 may be completely disconnected from the inside face of the outer shell 56. In other embodiments, outer mesh face 52 may not be completely disconnected from outer shell 56. For example, according to embodiments, all or a portion of the outer mesh face 52 may be adhered to the inside face of outer shell 56.

Although the shell material is referred to as “substantially solid,” embodiments are envisioned where the shell material has some degree of porosity, e.g., containing pores sized large enough to facilitate escape of sweat vapors, but small enough to substantially prevent penetration by wind, rain, or snow. Although embodiments of the shell material may have some degree of porosity, generally, the pores may not be visible to the human eye. Outer shell 56 and inner shell 58 may be the same fabric or different fabrics. According to embodiments, inner and outer shells 56 and 58 may include layers of tightly woven or knitted cotton/nylon blends, nylon and nylon blends, polyester and polyester blends. According to embodiments, inner and/or outer shells 56 and 58 comprise a waterproof breathable laminated material (such as GORE-TEX®) including, for example, an outer face fabric, a membrane, and an inner liner laminated together. According to embodiments, inner and/or outer shells 56 and 58 may be constructed from a laminated or coated waterproof material, such as those made by W.L. Gore & Associates, Inc. of Newark, Del., eVent Fabrics of Overland Park, Kans.; Toyota Tsusho of Nagoya, Japan; Amaterrace Inc. of Osaka, Japan; TORAY® of Tokyo, Japan, and PERTEX® of Tokyo, Japan; however, other fabrics known in the art may alternatively be used.

As shown in FIG. 6A, according to embodiments, the three-dimensional mesh 48 may have pores visible to the human eye. The outer mesh face 52 and the inner mesh face 50 may contain a matrix of pores. The pore sizes of the outer mesh face 52 and the inner mesh face 50 may be the same or different sizes. According to an embodiment, the mesh pile fibers 54 may be spaced from each other. According to an embodiment, the three-dimensional mesh 48 may include layers of cotton/nylon blends, nylon and nylon blends, polyester and polyester blends, polyamide, polypropylene, or other synthetic textile. According to an embodiment, the three-dimensional mesh is a polyester double knit with an approximate thickness of about 2 mm. According to an embodiment, other mesh thicknesses may be used to provide adequate air space between the body of the wearer and the waterproof layer. According to an embodiment, the plurality of ventilation panels may contain three-dimensional mesh with varying pore sizes, thicknesses, and materials. According to an embodiment, the three-dimensional mesh may have a thickness of about 1 mm to about 5 mm. In another embodiment, the three-dimensional mesh may have a thickness of about 2 mm to about 4 mm. According to embodiments, the plurality of ventilation panels may be made from three-dimensional mesh such as Fukui Warp Knitting made by Fukui Tateami Co. of Fukui, Japan, and double knit mesh made by Burltex of Hong Kong, China; however, other mesh known in the art may alternatively be used.

According to an embodiment, jacket 10 may be constructed using various materials and construction techniques. For example, all or parts of jacket 10 may be constructed from synthetic and/or natural fiber materials or fabrics, such as cotton, cotton blends, nylon, nylon blends, polyester, polyester blends, polyamide, and polypropylene. Other materials and/or combinations of materials will be identifiable by one of ordinary skill in the art based on this disclosure depending on the type and style of garment and/or intended use of the garment.

According to an embodiment, all or a portion of the fabric for jacket 10 may be coated, for example, with a durable water repellent (DWR) or other coating. According to an embodiment, jacket 10 may be constructed by joining multiple panels of material using techniques such as, for example, sewing, gluing, bonding, adhering, taping, seam sealing, or ultrasonic bonding. According to an embodiment, the jacket 10 may include additional features, such as pockets, loops, toggles, draw cords, gussets, vents, and flaps.

In the foregoing description, reference is made to “stitching” various parts of jacket 10 together. However, one of ordinary skill in the art will understand, based on this disclosure, that other construction techniques may alternatively be used, for example, without limitation, mechanical bonding, adhesives, lamination, ultrasonic welding, seam taping, or other technique known in the art or a combination of these applications.

While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not limitation. Thus, the breadth and scope of the present invention should not be limited by any of the above-described embodiments, but should instead be defined only in accordance with the following claims and their equivalents. 

What is claimed:
 1. A garment, comprising: a garment shell; and a ventilation region, wherein the ventilation region comprises a three-dimensional mesh member attached to the garment shell.
 2. The garment of claim 1, wherein the three-dimensional mesh member has an edge and a face, wherein the edge of the three-dimensional mesh member is attached to the shell.
 3. The garment of claim 2, wherein only the edge of the three-dimensional mesh member is attached to the garment shell.
 4. The garment of claim 1, wherein the shell comprises a material having a waterproof breathable membrane laminated to an outer layer.
 5. The garment of claim 1, wherein the garment is a jacket further comprising a yoke region and a hood, wherein the ventilation region is located at one or both of the yoke region and the hood.
 6. The garment of claim 5, further comprising: an attachment member connected to the garment shell; and a selective ventilation panel comprising three-dimensional mesh attached to the attachment member.
 7. The garment of claim 1, wherein the garment shell further comprises: a first front part having a first fastener member; and a second front part having a second fastener member, wherein the first fastener member is configured to be selectively fastened to the second fastener member; wherein the selective ventilation panel is located at the first front part of the shell adjacent to the first fastener member.
 8. The garment of claim 7, wherein the first fastener member comprises a far-side fastener member and a close-side fastener member, and the selective ventilation panel is located between the far-side fastener member and the close-side fastener member.
 9. The garment of claim 8, wherein the second fastener member is configured to be selectively fastened in either a first position to the far-side fastener member or a second position to the close-side fastener member.
 10. The garment of claim 9, wherein the first fastener member and the second fastener member comprise a zipper.
 11. The garment of claim 9, wherein, when the second fastener member is selectively fastened in the first position, the ventilation region is substantially covered by the second front part; and wherein, when the second fastener member is selectively fastened in the second position, the selective ventilation panel is exposed.
 12. The garment of claim 1, wherein the three-dimensional mesh member defines a thickness substantially perpendicular to the garment shell that is greater than a thickness of the garment shell.
 13. The garment of claim 1, wherein the three-dimensional mesh member defines a thickness substantially perpendicular to the garment shell that is between about 1 mm and about 5 mm.
 14. The garment of claim 1, wherein the three-dimensional mesh member defines a thickness substantially perpendicular to the garment shell that is between about 2 mm and about 4 mm.
 15. The garment of claim 1, wherein a porosity of the three-dimensional mesh member is greater than a porosity of the garment shell.
 16. A garment comprising: a three-dimensional mesh panel; and an outer layer; wherein the three-dimensional mesh panel comprises a face and an edge; wherein the outer layer overlays the three-dimensional mesh panel; wherein the three-dimensional mesh panel is connected to the outer layer at the edge of the three-dimensional mesh panel and the face of the three-dimensional mesh panel is at least partially disconnected from the outer layer.
 17. The garment of claim 16, wherein the outer layer comprises a waterproof breathable membrane.
 18. The garment of claim 16, wherein the three-dimensional mesh panel defines a thickness substantially perpendicular to the outer layer that is greater than a thickness of the outer layer.
 19. The garment of claim 16, wherein the three-dimensional mesh panel defines a thickness substantially perpendicular to the outer layer that is between about 1 mm and about 5 mm.
 20. The garment of claim 16, wherein a porosity of the three-dimensional mesh panel is greater than a porosity of the outer layer.
 21. The garment of claim 16, wherein the three-dimensional mesh panel is a knit of material selected from the group consisting of polyester, polyamide, polypropylene, or other synthetic textile.
 22. The garment of claim 16, wherein the three-dimensional mesh panel and the outer layer are connected by seam sealing.
 23. The garment of claim 16, wherein the three-dimensional mesh panel and the outer layer are connected by stitching around the edge of the three-dimensional mesh panel.
 24. The garment of claim 16, wherein the outer layer comprises a water repellent coating.
 25. A method of manufacturing a garment, comprising: providing a plurality of outer garment layer panels; providing a three-dimensional mesh panel; attaching the three-dimensional mesh panel to at least one of the outer layer garment panels to form at least one ventilation panel; and attaching the plurality of outer garment layer panels to form the garment.
 26. The method of claim 25, further comprising: seam sealing together the plurality of outer garment layer panels to form the garment.
 27. The method of claim 25, further comprising: stitching together the plurality of outer garment layer panels to form the garment.
 28. The method of claim 25, wherein at least one of the plurality of outer garment layer panels comprises a waterproof breathable membrane.
 29. The method of claim 25, wherein attaching the three-dimensional mesh panel to the at least one of the outer garment layer panels comprises attaching edges of the three-dimensional mesh panel to the at least one outer garment layer panels.
 30. The method of claim 29, wherein only the edges of the three-dimensional mesh panel are attached to the at least one outer garment layer panels.
 31. The method of claim 25, wherein the at least one ventilation panel comprises at least one or more of a hood or a yoke of a jacket. 